Modeling and numerical analysis of line-cell conversion problems

Abstract

In this paper we define a line-cell conversion problem that has been reported as a new technical innovation in Japanese industry, and we construct a mathematical model to describe it. By numerical analysis of the model based on simulation experiments, we gain insight into line-cell conversion problems, such as (1) how many cells should be formatted, (2) how many workers should be assigned in each cell, and (3) how many workers should be rested on a shortened conveyor line when a conveyor assembly line is converted into cells, in order to optimise system performance, which is defined as the total throughput time and total labour power. Therefore, the model can be used as an evaluation tool in the case where (i) a company wants to change its production system (usually a belt conveyor line) to a new one (including cellular manufacturing), and (ii) a company wants to evaluate the performance of its converted system.